Practice
Application Modernization · IoT
Application Modernization · IoT
Modernise the plant floor.
Beat the AMC clock.
Wonder Cement's in-plant logistics ran on a high-cost legacy Autoplant platform — slow, rigid, and tied to a vendor's renewal date. Kansoft replaced it with a scalable, real-time, IoT-enabled operations system on .NET microservices and Azure, delivered in three months, ahead of AMC renewal.
3 months · two phases Autoplant replaced Zero plant downtime
The Client & Context
A cement manufacturer racing the clock — replace a legacy plant platform before AMC renewal, without losing a shift.
Wonder Cement runs large-scale production facilities with complex in-plant logistics, vehicle movement, and material handling operations.
The existing platform — an Autoplant deployment that had quietly accumulated technical debt — was carrying high recurring AMC costs, slow response times, and an architecture that made every enhancement a project of its own. To improve operational efficiency and cut infrastructure costs, the organization needed to replace it with a modern, scalable, automated logistics system.
The constraint that defined the engagement: the new platform had to be live before the existing AMC came up for renewal. That meant a modernization timeline measured in months, not quarters — and zero tolerance for a downed plant.
Key Challenges
Five constraints that made the legacy platform unworkable.
High cost, low flexibility, manual workflows — and a deadline the legacy vendor controlled.
01
Legacy system limitations
The existing Autoplant system carried high AMC costs and slow response times — a recurring tax on operational efficiency without a corresponding upside.
02
Limited flexibility
Enhancements were expensive and time-consuming. The legacy architecture restricted future scalability and locked the business out of new operational use cases.
03
Manual operations
Heavy dependency on manual workflows across vehicle movement, weighment, and coordination — which translated into operational delays and human error in a process where neither is cheap.
04
Lack of real-time visibility
No centralized operational dashboards. Decisions about plant flow happened on lagged information, when they happened at all.
05 · AMC deadline
And all of it sitting on a deadline the legacy vendor controlled.
The AMC renewal window forced the timeline. A new platform had to be production-grade and running plant operations before the existing contract lapsed — which meant compressing a typical 9–12 month modernization into a fraction of that, without sacrificing the architectural quality that made the project worth doing.
Our Approach
A modernization-first strategy — scalable architecture, automation, and IoT, sequenced for speed.
Kansoft combined scalable architecture design, automation, and IoT integration. Each phase was scoped to land in production, not just demo well in a review.
PHASE 01
Workflow Assessment
Analyzed existing Autoplant workflows, bottlenecks, and operational dependencies — including the integrations the legacy platform held together implicitly.
PHASE 02
Platform Re-Architecture
Designed a microservices architecture for scalability, flexibility, and system responsiveness — sized for the plant's current scale and the next phase of operational use cases.
PHASE 03
Custom Application Development
Built a modern in-plant logistics platform using .NET Core and Angular — chosen for the team's existing skill base and Azure-native deployment.
PHASE 04
IoT Enablement & Cloud Foundation
Integrated plant devices and operational systems for real-time data exchange; leveraged Azure services to ensure high availability, performance, and transaction reliability under plant load.
Solution Delivered
What we built — the platform, in six modules.
A complete replacement for Autoplant: a modern platform foundation, IoT integration with plant devices, automated vehicle sequencing, live operational dashboards, a cloud infrastructure backbone, and an integration surface that ties everything to plant operations.
Modern In-Plant Logistics Platform
Complete replacement of the legacy Autoplant system, on a flexible, scalable architecture that supports future enhancements without re-platforming. Built on .NET Core and Angular — production-ready, not migration-ready.
IoT-Enabled Plant Operations
Integration with weighment systems, loading slips, and announcement systems, with real-time vehicle sequencing and operational coordination across stations. Plant devices feed the platform — not a parallel data layer.
Automated Vehicle Sequencing
Intelligent sequencing that reduces manual intervention at the gate, improving turnaround time and queue throughput. Sequencing decisions surface on the same dashboards as weighbridge and load data.
Real-Time Operational Dashboards
Centralized visibility into plant logistics, vehicle flow, and workflow status — enabling faster, data-driven decisions during a shift, not after it, with drill-through from KPI to event-level detail.
Cloud-Based Infrastructure Foundation
Azure Blob Storage for scalable data management across plant data volumes, Azure Service Bus for transaction orchestration across microservices, and Azure Cache for high-performance master data access at plant tempo.
Plant Systems & Workflow Integrations
Weighment systems, vehicle sequencing displays, and plant announcement systems — all wired into the platform. Internal logistics workflows extended end to end, with an integration surface designed to add new devices and downstream systems without rework.
Platform Architecture
Technology Stack
Built on a stack chosen for plant tempo and engineering reliability.
Every choice maps to a plant-floor constraint — sub-second response, transaction integrity under load, and the ability to keep adding integrations without breaking what's already running.
.NET Core microservices
Service-per-capability architecture that scales and evolves independently
Angular web platform
Dashboard-first UX for operators, supervisors & management
Microsoft Azure
Production deployment on a mature data & messaging platform
Azure Blob Storage
Scalable object storage for operational data & document artifacts
Azure Service Bus & Cache
Transaction orchestration plus fast master-data access on the hot path
IoT & plant systems
Weighment, sequencing displays & announcements wired in, not bolted on
Measured Outcomes
From a vendor's clock to a platform you control.
Six things changed between the legacy Autoplant deployment and the platform running the plant floor today.
3 mo
Delivered, two phases
Live before the legacy AMC renewal window
Zero
AMC renewal cost
Recurring vendor dependency removed
Real-time
Operational visibility
Live dashboards across plant processes — a first
6
Platform modules
One integrated system on flexible microservices
| Metric | Before | After |
|---|---|---|
| System performance | Slow legacy platform | Fast, responsive system |
| AMC costs | High recurring costs | Optimized infrastructure model |
| Operational processes | Manual & fragmented | Automated workflows |
| Vehicle sequencing | Manual coordination | Automated sequencing |
| Data visibility | Limited operational tracking | Real-time dashboards |
| Platform scalability | Rigid architecture | Flexible microservices |
What Changed for the Business
Beyond the platform — four ways the work compounded.
The replacement removed a recurring cost and a vendor dependency. What the plant gained was a foundation for the next decade of operational change.
Operational efficiency
Automation across logistics workflows significantly reduced manual coordination and improved operational throughput across shifts.
Cost optimization
Replacing the legacy platform ahead of AMC renewal removed recurring vendor cost and reduced dependency on a single legacy supplier.
Real-time decision making
Live dashboards enabled faster monitoring and proactive management of plant operations — decisions during a shift, not after it.
Future-ready infrastructure
The microservices architecture provides flexibility for rapid enhancements and the next phase of operational use cases without re-platforming.
Engagement Snapshot
How the work was shaped.
Architecture
.NET Core microservices · Angular
Cloud
Microsoft Azure · Blob · Service Bus · Cache
Timeline
2 phases · 3 months
Why Kansoft
The capability mix this engagement required.
A plant cutover under live load, on a deadline a vendor controlled, is a specific kind of hard. It needs industrial domain, modernization discipline, and IoT integration — together.
Industrial & manufacturing platforms Strong expertise in plant-floor systems — not generic enterprise patterns retrofitted to a factory.
Legacy system modernisation Deep experience replacing legacy platforms, including phased cutover under live operational load — without losing a shift.
IoT & system integration Capability to integrate plant devices and operational systems directly into the platform — a connected plant floor, not a parallel data layer.
Cloud-first Azure delivery Proven Azure engineering — and the discipline to ship a production-grade platform under a hard, vendor-controlled deadline.
Ready to build something like this?
If your plant systems are running on a vendor timeline you don't control, the next call is the one worth having.
We help manufacturing organizations modernize legacy plant platforms, integrate IoT and operational systems, and build the cloud-native foundation that supports the next decade of operational change. If that's where you're headed, let's talk.
Confidential · No procurement obligation · Response within one business day